PROJECT ON STUDY OF COMMUNICATION PROBLEM IN ABB DRIVE - Copy

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PROJECT ON
THE STUDY OF DRIVE COMMUNICATION FAILURE
DEPARTMENT: NEW BAR MILL
By
AMANRAJ SINGH PADAN
OF
KALINGA INSTITUTE OF INDUSTRIAL TECHNOLOGY
BHUBANESWAR
Guide:
Mr. Sushil Kumar Tripathy
(Senior Manager, IEM)
TATA STEEL LIMITED JAMSHEDPUR
CERTIFICATe

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This is to certifythat the summer trainee:
AMANRAJ SINGH PADAN OF KALINGA INSTITUTE OF
INDUSTRIAL TECHNOLOGY OF BHUBANESWAR, ODISHA has
completed his project on the topic:
THE STUDY OF DRIVE COMMUNICATION
FAILURE under the guidance of Mr. SUSHIL KUMAR
TRIPATHY, SENIOR MANAGER (IEM)TATA STEEL,
JAMSHEDPUR.
The duration of the training was from 05-05-2015 to 06-06-2015.

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ACKNOWLEDGEMENT
First of all I would like to express our deep sense of gratitude to Mr.
SUSHIL KUMAR TRIPATHY for giving his consent to carry out our
project in Tata Steel.
My sincere thanks to Mr. MANOJIT ROY AND Mr.BIJU ABRAHAM
for his guidance and help which has been very useful in completing this
project.
My Sincere Gratitude to Mr.VINIT SHAH Chief, New Bar Mill.
I am also very thankful to Mrs. NILU KUMARI AND Mr.SURAJ
KUMAR for his valuable support and guidance without which this
project would not have been a successful one.
I would also like to thank all the officers, staffs and workers of New Bar
Mill, TATA STEEL for their consistent efforts to assist me in my project.
I would like to express my gratitude to Ms.C KHULLAR In-Charge, Vacation
Training, SHAVAK NANAVATI TECHNICAL INSTITUTE (SNTI), for giving me
the opportunity for in planttraining in Tata steel

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CONTENTS
Sl
No.
Topics Page
No.

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INTRODUCTION
(TATA TISCON and NEW BAR MILL)
1 INTRODUCTIONON TATA TISCONAND NEW BAR MILL 5-10
2 NBM AUTOMATIONCONFIGURATIONDIAGRAM 11
3 INTRODUCTIONABOUT PLC 12-15
4 DESCRIPTIONABOUT DRIVE SECTION 15-17
5 DRIVE PLC COMMUNICATIONSET UP AT NBM 18
6 NETWORK LAYOUT 19
7 COMPONENTS OF NETWORKLAYOUT 19-20
8 PROBLEMS 20-25
9 PROBLEM DATA HISTORY 26
10 ABB RECOMMENDATION 27
11 NBM ACS 600 LINE BUS FAULT 27-28
12 PROBLEM AND NETWORK MODIFICATION IN RECENT
YEARS
28-35
13 PROFIBUS 36-38
14 ETHERNET ANDCABLE 38-40
15 CONCLUSION 41

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Tata Steel, the 12th largest steel producer in the world, is one of the first few companies
in India to introduce Thermo Mechanically Treated reinforcement bars, using the latest
technology - the ‘Tempcore Process’ (introduced in India for the first time which imparts
high strength to the bar as against cold twisting, a traditional manufacturing process.
TATA TISCON 500D is superior to traditional rebars in the market owing to low levels of
Sulphur & Phosphorus (S&P) which are harmful impurities in steel. TATA TISCON is
produced through a combination of superior processes. The steel for TATA TISCON
500D is produced through primary steel making route, using iron ore from captive
mines. It is subsequently processed through the blast furnace, LD & LF (ladle refining)
to refine the steel to the fullest extent and continuously cast into billets. The resultant
steel is of superior quality, containing no harmful ingredients (like Sulphur and
Phosphorus) and ensures the desired and consistent properties in the rebar.
Tata Steel has set up a new bar mill with the latest technology supplied by Morgan,
USA. This mill has both horizontal and vertical stands, a series of zero-tension loopers
and a fully automated bar bundling and master bundling system. Spacious billet yard for
cast-wise stacking of billets, reheating furnace, pre-finishing and finishing mill, cold
shear to cut bars, roughing mill, intermediate mill and the latest TMT facilities are the
other features of the bar mill. TATA TISCON 500D rebars are ‘hot rolled’ from steel
billets and subjected to PLC controlled on-line thermo-mechanical treatment in three
successive stages:

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(a)Quenching - The hot rolled bar leaving the final mill stand is rapidly quenched
by a special water spray system. This hardens the surface of the bar to a depth
optimized for each section through formation of martensitic rim while the core
remains hot and austenitic.
(b) Self Tempering - When the bar leaves the quenching box, the core remains
hot compared to the surface, allowing heat to flow from the core to the surface,
causing tempering of the outer martensitic layer into a structure called 'Tempered
Martensite.' The core still remains austenitic at this stage.
(c) Atmospheric Cooling - This takes place on the cooling bed
where the austenitic core is transformed into a ductile ferrite-pearlite structure. Thus the
final structure consists of an optimum combination of a strong outer layer (tempered
martensite) with a ductile core (ferrite-pearlite). This gives TATA TISCON 500D its
unique combination of higher strength and ductility.

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Key Highlights of NBM:
• Best ever Production in FY13, Fy’14 H1 and Q3
• Best ever monthly production(75710 MT, May’13)
• Increased 10 mm mill speed from 27m/s to 31m/s.
• Consistent mill operation of 12mm @ 27 m/s.
• Reduction of set up time to 3 hrs and Reduction in planned shutdown hours.
• Zero customer complaint since 2011
• Reduction in inspection & in process rejections
• Zero LTI.
• 100% employee involvement in improvement initiatives.
• One kaizen team, Aquarius won par excellence NCQC award.
• NBM Won JWQC apex winner award for DM.

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Technical Specification of Billets:
Area (mm2) Length (m) Weight (kgs) Bendness DD
150*150 11.75 - 11.98 2110 kgs
<70 mm/12
mm
<17 mm
Chemical Composition of Re-bars produced:

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MILL OVERVIEW
• Mill configuration is with 16 No-Housing stands. The first 8 stands are in a
vertical/horizontal configuration to avoid twist rolling of the 150mm billet.
• Stands 9 to 12 are all horizontal stands with Stands 13 to 16 in single line of 4
stands for Phase 1 and stands 17 to 22 are part of the 6-stand No Twist Mills and
are in two separate lines.
• Shears are provided after Stand No. 8, before the No Twist Mills and after the
water boxes for dividing products to the cooling beds.
• Water boxes are provided for quenching of re-bars 8 mm to 16 mm to produce
HYQST products.
• Powered slitter is provided after stand 16H and a provision has been kept to add
another powered slitter after stand 12H. The process section is then finish rolled
through the No Twist Mills.
• Bars 8, 10, 12 and 16 mm rolled in single strand through stands 1V to 16H are
slit 2-way and rolled through two groups of No Twist Mill stands 17 through 22.
• The downstream facilities for cooling, bundling and tying equipment are designed
with flexibility in terms of rolling small sizes at higher speeds, ease of adjusting
equipment during the learning curve and providing time for maintenance and
changes in the mill without affecting productivity.
• Bars emerging from two lines after the dividing shears are distributed bed outlet.
• Bar in each line is fed alternately to two delivery trough lines with the help of a
diverter switch located in front of each dividing shear.
• The bars are braked by a set of pinch rolls before entering the high-speed entry
equipment to the cooling bed. The bars thus collected are released through a set
of guides to the notch of the cooling bed. (TWIN ROTARY DRUM DELIVERY
SYSTEM for high speed entry to cooling bed )

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• Two such lines discharge bars to one side of the cooling bed, and the rakes
make a stroke after two sets of bars are dropped on the notches.
• After the bars are sufficiently cooled, the front end of the bars will get aligned by
the aligning rollers to improve yield while cutting order lengths 6 to 12m from the
cooling bed lengths of 72 m.
• At the discharge of the rake section of the cooling bed, bars drop on the adjacent
chain transfer provided with compartments and indexing features. This will assist
in collecting a number of pre-selected bars that will form a pre-defined bundle.
• Once the chain is full with layer of sub-bundles a tray transfer mechanism will
pick up the layer and deliver the same to the cooling bed run-out roller table,
having the same width and also with compartments to accommodate pre
selected sub-bundle layer in each segment.
• The layer will be run towards the cold shear for cutting order lengths with the help
of a gauge head. The cold shear is equipped with rapid blade change facilities.
• Downstream the cold shear four outlets for bundling of re bars are designed to
handle 6 to 12 m in single row and Station 4 is basically designed with short
separation facility.
• At the sub-bundling station the system is capable of forming 3 to 5 ton bundles
with wire ties.
• The loose bundle is held firmly by bundle forming units, before and after the
strapping machine, to have a compact round bundle formed before the strapping
operation is initiated. There is also the facility of loose bundles handling facility,
which ensures 100% compact bundle tying before weighing.
• The strapped bundle is transported on another roller table to the weigh scale
located along the roller table. Once the weighing is complete the chain transfer
removes the weighed and tagged bundle away from the roller table and
advances the same to the unloading point of the chain conveyor.
• The bundles are ready for removal by the shipping overhead cranes from two
unloading stations, located apart on either side and stacked for dispatch.

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NBM AUTOMATION CONFIGURATION DIAGRAM

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INTRODUCTION ABOUT PLC
A programmable logic controller, PLC, or programmable controller is a digital
computer used for automation of typically industrial electromechanical processes, such
as control of machinery on factory assembly lines, amusement rides, or light fixtures.
PLCs are used in many machines, in many industries. PLCs are designed for multiple
arrangements of digital and analog inputs and outputs, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact. Programs to control
machine operation are typically stored in battery-backed-up or non-volatile memory. A
PLC is an example of a "hard" real-time system since output results must be produced
in response to input conditions within a limited time, otherwise unintended operation will
result.
Programmable logic relay (PLR)
In more recent years, small products called PLRs (programmable logic relays), and also
by similar names, have become more common and accepted. These are much like
PLCs, and are used in light industry where only a few points of I/O (i.e. a few signals
coming in from the real world and a few going out) are needed, and low cost is desired.
These small devices are typically made in a common physical size and shape by
several manufacturers, and branded by the makers of larger PLCs to fill out their low
end product range. Popular names include PICO Controller, NANO PLC, and other
names implying very small controllers. Most of these have 8 to 12 discrete inputs, 4 to 8
discrete outputs, and up to 2 analog inputs. Size is usually about 4" wide, 3" high, and
3" deep. Most such devices include a tiny postage-stamp-sized LCD screen for viewing
simplified ladder logic (only a very small portion of the program being visible at a given
time) and status of I/O points, and typically these screens are accompanied by a 4-way
rocker push-button plus four more separate push-buttons, similar to the key buttons on

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a VCR remote control, and used to navigate and edit the logic. Most have a small plug
for connecting via RS-232 or RS-485 to a personal computer so that programmers can
use simple Windows applications for programming instead of being forced to use the
tiny LCD and push-button set for this purpose. Unlike regular PLCs that are usually
modular and greatly expandable, the PLRs are usually not modular or expandable, but
their price can be two orders of magnitude less than a PLC, and they still offer robust
design and deterministic execution of the logics.
LADDER DIGRAM
Machine control design is a unique area of engineering that requires the knowledge of
certain specific and unique diagramming techniques called ladder diagramming.
Although there are similarities between control diagrams and electronic diagrams, many
of the component symbols and layout formats are different. This chapter provides a
study of the fundamentals of developing, drawing and understanding ladder diagrams.
We will
Begin with a description of some of the fundamental components used in ladder
diagrams.
Programmable controllers can implement the entire “old” ladder diagram Conditions and
much more. Their purpose is to perform this control Operations in a more reliable
manner at lower cost. A PLC implements, in Its CPU, all of the old hardwired
interconnections using its software instructions. This is accomplished using familiar
ladder diagrams in a manner that is transparent to the engineer or programmer. As you
will see throughout this Book, knowledge of PLC operation, scanning, and instruction
programming is vital to the proper implementation of a control system.
SCAN TIME
A PLC program is generally executed repeatedly as long as the controlled system is
running. The status of physical input points is copied to an area of memory accessible
to the processor, sometimes called the "I/O Image Table". The program is then run from
its first instruction rung down to the last rung. It takes some time for the processor of the

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PLC to evaluate all the rungs and update the I/O image table with the status of outputs.
This scan time may be a few milliseconds for a small program or on a fast processor,
but older PLCs running very large programs could take much longer (say, up to 100 ms)
to execute the program. If the scan time were too long, the response of the PLC to
process conditions would be too slow to be useful.
COMMUNICATION
PLCs have built-in communications ports, usually 9-pin RS-232, but optionally EIA-
485 or Ethernet. Modbus, BAC net, or DF1 is usually included as one of
the communications protocols. Other options include various fieldbuses such as Device
Net, Profibus or Profinet. Other communications protocols that may be used are listed in
the List of automation protocols.
REDUNDANCY
Some special processes need to work permanently with minimum unwanted down time.
Therefore, it is necessary to design a system which is fault-tolerant and capable of
handling the process with faulty modules. In such cases to increase the system
availability in the event of hardware component failure, redundant CPU or I/O modules
with the same functionality can be added to hardware configuration for preventing total
or partial process shutdown due to hardware failure.

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Allen-Bradley PLC
DESCRIPTION
(About Drive Sections)
A drive section includes one to three inverters depending on the Inverter power rating.
As a standard the inverters are protected with fuses. An optional
Disconnecting switch can be selected to disconnect the inverter from
The DC supply.
The inverter main circuit includes DC capacitors, discharging resistors,
Clamping capacitors and six Insulated Gate Bipolar Transistors. (IGBTs).
Inverter Module Frame
Sizes
Inverter modules are installed into cubicles depending upon the
Physical size of the module. The frame sizes are: R2i, R3i, R4i, R5i, R6i,
R7i, R8i, R9i, R10i, R11i or R12i.

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ACS 600 AC450
ADVANT CONTROLLER450
The Advant Controller 450 consists of a CPU sub-rack with two positions for redundant
CPU modules, sub-module carriers for communication sub-modules as well as a part
with regulatory and backup power. The S100 I/O is located in subsequent I/O sub-racks,
which can be placed in cabinets adjacent to the CPU cabinet or in a remote location
separated by optical fiber.
The Advant Controller 450 covers a wide range of functions such as:
 Regulatory control including advanced PID and self-tuning adaptive control.
 Logic and sequence control.
 Data and text handling, arithmetic, and positioning.
 Self-configuration capabilities which make it possible to add hardware while the
controller is in full operation
 Full on-line configuration capabilities while the application is running.

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 Support for a wide range of central and distributed I/O modules for maximum
configuration possibilities, with a maximum I/O capacity of 5700 I/O points.
 Support for local and central operator interface for manual control operations, event and
alarm handling, trend curve presentation etc.
 Interoperability concerning all communication levels from plant floor fieldbuses to high-
speed plant network.
 Support for Profibus ABB’s redundant Advant Fieldbus 100, and other protocols.
 Time synchronization with other nodes in an automation system at an accuracy better
than 3 ms. The controller and its I/O can time tag events with a resolution of 1ms
 Backup of system and application RAM with separate power supply, local battery or
station battery as well as back-up of application on flash PROM cards.
ACS 600
The ACS 600 product family includes: a fully customized product for demanding system
applications (ACS 600 MultiDrive) drives for general purpose standard applications
(ACS 600 SingleDrive) drives for special applications such as positioning and cranes
(ACS 600 CraneDrive, ACS 600 MotionControl) drives for special branches (ACS 600
MarineDrive) ACS 600 MultiDrive is designed for the optimum configuration in multiple
drive applications. Whether an application involves a drive or two hundred drives, there
is an optimum configuration to meet the application need. ACS 600 MultiDrive consists
of four different section types: a supply section; a braking section, several drive sections
and control sections. The section type determines which type of equipment are in each
section cubicle. The modularity is a key-feature of the construction.

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DRIVE PLC COMMUNICATION SET UP AT NBM:
PROTOCOL:ADVANT FIELD BUS 100
Advant Fieldbus 100 (AF 100) is a high performance fieldbus, which is used for:
• Communication between Advant Controllers
• Communication between Advant Controllers and S800 I/O Stations, AC 800M
controllers, AC 100 OPC Server, and the equipments developed and sold by other ABB
companies.
In an AF 100 bus, it is possible to reach up to 80 stations within a total physical distance
of up to 13300 meters (43300 feet).
Advant Fieldbus supports three transmission media:
• Twisted pair (Twp)
• Coaxial (RG59 and RG11)
• Optical media.
An AF 100 bus can be built up with all the three media, where a part of one kind of
media is a specific segment.
The following rules apply to the segments:
• To each twisted pair segment, 32 stations can be connected, and the maximum
segment length is 750 meters (2500 feet)
• The coaxial segment can be:
– 300 meters (1000 feet) with cable RG59 or
– 700 meters (2300 feet) with cable RG11.
• The optical media is only used in point-to-point communication, and it allows the total
length of a bus segment to be up to 1700 meters (5500 feet).
• If back-to-back coupled optical segments are used, it is possible to reach up to a
physical length of 13300 meters (43300 feet).

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Network layout
COMPONENTS OF NETWORK LAYOUT
RDCO Communication modules
The RDCO-0x DDCS Communication options are add-on modules for the • RMIO Motor
Control and I/O board (also part of RDCU control units) • BCU control units. RDCO
modules are available factory-installed as well as retrofit kits. The RDCO module
includes the connectors for fiber optic DDCS channels CH0, CH1, CH2 and CH3. The
usage of these channels is determined by the application program; see the Firmware
Manual of the drive. However, the channels are normally assigned as follows: CH0 –
overriding system (eg. fieldbus adapter) CH1 – I/O options and supply unit CH2 –
Master/Follower link CH3 – PC tool (ACS800 only). There are several types of the
RDCO. The difference between the types is the optical components. In addition, each
type is available with a coated circuit board, this being indicated by a “C” suffix, eg.
RDCO-03C.

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MODULE
TYPE
OPTICAL COMPONENT TYPE
CH0 CH1 CH2 CH3
RDCO-01(C) 10 MBd 5 MBd 10 MBd 10 MBd
The optical components at both ends of a fiber optic link must be of the same type for
the light intensity and receiver sensitivity levels to match. Plastic optical fiber (POF)
cables can be used with both 5 MBd and 10 MBd optical components. 10 MBd
components also enable the use of Hard Clad Silica (HCS) cables, which allow longer
connection distances thanks to their lower attenuation.
PROBLEMS:
The Incidence –BPRA2 Bus Fault :
Department : New Bar Mill
Section : IEM
Date : 16.11.2010
Time : 11:30 PM
Location : BPR -A2
Delay : 60 Min.
Observations:
1. Bar Overshoot in line A.
2. BPR A2 tripped in bus fault

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Action Taken:
1. Drive reset
2. Tightened the FO cable between NDBU & RDCU
Analysis:
1. FO cable connector may become loose.
2. Due to Dust/vibration there may be a loss in communication at connections
Probable reasons of failure:
1. Aging of FO cable
2. Aging of FO connectors
3. Dusty environment
Recommendations:
1. Schedule maintenance and testing of FO cables and connections.

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The Incidence –BPRA2 Bus Fault
Section : IEM
Date : 18.12.2010
Time : 07:30 PM
Location : BPR
Delay : 184Min.
Observations:
3. DSA cobble detect alarm.
4. BPR A2 tripped in bus fault
Action Taken:
1. Replaced the FO cable between NDBU & RDCU
Analysis: -
Defective FO cable were checked and found communication loss (dB is
Higher than normal value. (Greater than 15 dB)
Due to Dust/vibration there may be a loss in communication at
1. Dusty environment
Recommendations:
1. Schedule maintenance and testing of FO cables and connections.
All dust entry points should be sealed through filters at the door

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The Incidence – AF#100 Bus Fault in AM1CPU3 during shutdown
job.
Section : IEM
Date : 24.01.2014
Time : 10:00 AM
Location : Lineup#1
Delay--- : Nil
Observations:
 AF100_Bus4 of AM1_CPU3 made down to change the end terminator
and CI810 to NDBU FO cable by making pin ‘IMPL’ to 0
 After changing the end terminator & FO cable, bus tried to restart by
making pin ‘IMPL’ to 1.
 During restarting, ‘AF#100S’ of Lineup#1 (station#42), ‘PHE’ (Peripheral
H/W error) warning came in the database element.
 During the BUS down time, the individual stations as well as drive units
should be made down.
 During restarting of BUS, the individual stations as well as drive units should
be restarted.
Action Taken:
 Tried to reset the error by making ‘IMPL’ & ‘SERVICE’ pins to 0 and to 1
but error was persisting
 Then restored the CI810 to NDBU FO cable, but no improvement found
 Then all the related drives RMIO and TSU’s CON2 power supply of
LU#1&2 recycled and then found working ok.

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Recommendations:
Sl. No
Recommendations Remarks
1 All AF#100 BUS TBM maintenance to be done immediately
COMMUNICATIONMODULE Faultcode: 7510
CAUSE: Fieldbus communication break detected on fieldbus module or on
communication channel CH0 receive.
WHAT TO DO: Check the connections of fieldbus adapter module. With an ABB Advant
overriding system check channel CH0 optical fibres between the RMIO board and
overriding system (or Nxxx type of fieldbus adapter). Test with new optical fibres. Check
the earthings of fieldbus cables.
Check that the node address is correct in the drive. Check the status of the fieldbus
adapter. See appropriate fieldbus adapter manual.
Check parameter settings of Group 51, if a fieldbus adapter is present. Check the
connections between the fieldbus and the adapter. Check that the bus master is
communicating and correctly configured.

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PROBLEM HISTORY
data taken from JUNE 2015 TO FEB 24 2015

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ABB RECOMENDATION
NBM ACS 600 lineup bus fault
Problem:
• At NBM we have frequent tripping of stand drives of line up #1 in bus fault from
last 2years.
• Recently the tripping has become very frequent.
Background:
• Lineup 1 is ACS 600 MultiDrive with 1 TSU and 5 inverter, bus fault is common in
inverter 1 and inverter 3.
• Drive communicates with PLC (AC450) via AF100 and CI-810 module. From C1
810 we have FO going to NDBU95 and from there it goes to RMIO via RDCO.
• From controller (PLC) AF 100 bus goes to lineup 2, from lineup 2 AF100 goes to
lineup 1 and terminates.
Action taken in past:
• FO cable changed from NDBU to RMIO, RDCO changed, and NDBU changed.
• light intensity checked found OK,
• terminating resistance of AF100 at CI 810 changed
Recommendation Status
Checking 24 volts of RDCU card Done
Grounding of RDCU card Done
Shorting unused FO channel of RDCO Done
Moving CI810 card of lineup 1and lineup 2
to PLC panel
Done
Monitoring FC duty Done
6 page checklist
To remove tube light choke from PLC panel

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Recent action:
• Power at RDCO card was checked and found OK.
• In shutdown from 4-6 December 2014, we modified network between lineup 2
and lineup 1. AF100 cable loop was shortened by shifting C1810 of lineup 1, in
same panel as lineup 2.
• On 30.12.2014 during section change we changed Af100 cable between lineup
2 and lineup 1 to make the length greater than 3 meters to avoid reflection as per
ABB
• In January 2015 we have shorted unused FO channel ( channel 1&2) of RDCO
with FO cable.(stand 1 and 6)
• In January 2015 we have provided extra grounding of the RDCU card (stand 1
and 6)
• In Feb 2015 we again modified the drive network. We moved both CI810 card of
lineup 2 and lineup 1 to PLC panel, HCS cable was laid from CI810 card in PLC
panel to BDBU in lineup 2 and 1.
• Also we have done trending of drive parameter FC duty in IBA.
Network modified recently (4-6 dec 2014)

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Modification and problem on 30 dec 2014
Based on ABB recommendation to avoid reflection in AF100 cable it was decided to
increase AF100 cable length from 1 mtrs to 3.5 mtrs, so cable between CI810 card of
lineup 2 and lineup was changed

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Modificationand problemon 11 Feb 2015
Lineup 1
FO cable replaced by AF100 cable and modem removed
Both CI 810 card of lineup 2 and lineup 1 moved to AM1 PLC panel
Stand 6 bus fault, 14 feb 2015 , FC duty trend

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• Stand 6 had bus fault, bus fault only happens in stand 1 and stand 6.
• Stand 1,5,7,8 ,6 are in lineup 1.
• Stand 2,3,4 are in lineup 2 .
• Lineup 1 and lineup 2 are in same AF100 bus( stand 1,2,3,4,5,6,7,8) , coming
from AM1 CPU3.
• Stand 9,10 are in lineup 2, stand 11,12 are in lineup 3
• Part lineup 2( stand 9, 10 ) and lineup 3 are in one AF100 bus coming from AM2
CPU1.
• FC duty is high(80 %) in some drives and it falls to 60 % when mill is not running

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Modification in RDCU /RDCO card
• Additional grounding done through cable
• Although card was grounded through mounting channel ,
Unused channel 1 and 2 RX TX shorted using FO cable

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ERROR LOG IN PLC FOR BUS FAULT
Action done on 4 march 2014 Regarding stand #6 bus fault.
• Stand #6 RDCU AND RDCO card changed.
• RTAC card changed for stand 6
• NDBU TO RDCU FO cable changed.
• CH# 3 and CH0 both FO cables changed.
• DB loss test for following FO cables was done.
• CH 0 NDBU to RDCO
• Line up 1NDBU to CI810
• Both results found o.k.
• Line up #1 NDBU channel changed for TSU and all its inverter e.g. stand#5, 6, 7,
8 and 1.

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Action taken on by NBM IEM in March 2014
Action before 4 march 2014
Lineup 1 all drive channel 3 communication to IBA server stopped.
After: termination of CI810 done using TC505 and prefabricated trunk cable

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Before: CI810 terminating done using AF100 cable
AF100 bus modification after ABB suggestion based on checklist

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PROFIBUS
PROFIBUS (Process Field Bus) is a standard for fieldbus communication in automation
technology and was first promoted in 1989 by BMBF (German department of education
and research) and then used by Siemens.
The goal was to implement and spread the use of a bit-serial field bus based on the
basic requirements of the field device interfaces. For this purpose, member companies
agreed to support a common technical concept for production (i.e. discrete or
factory automation) and process automation. First, the complex communication protocol
Profibus FMS (Field bus Message Specification), which was tailored for demanding
communication tasks, was specified.
There are two variations of PROFIBUS in use today; the most commonly used
PROFIBUS DP, and the lesser used, application specific, PROFIBUS PA:
• PROFIBUS DP (Decentralised Peripherals) is used to operate sensors and
actuators via a centralised controller in production (factory) automation applications.
The many standard diagnostic options, in particular, are focused on here.
• PROFIBUS PA (Process Automation) is used to monitor measuring equipment via a
process control system in process automation applications. This variant is designed
for use in explosion/hazardous areas (Ex-zone 0 and 1). The Physical Layer (i.e. the
cable) conforms to IEC 61158-2, which allows power to be delivered over the bus to
field instruments, while limiting current flows so that explosive conditions are not
created, even if a malfunction occurs. The number of devices attached to a PA
segment is limited by this feature. PA has a data transmission rate of 31.25 kbit/s.
However, PA uses the same protocol as DP, and can be linked to a DP network
using a coupler device. The much faster DP acts as a backbone network for
transmitting process signals to the controller. This means that DP and PA can work
tightly together, especially in hybrid applications where process and factory
automation networks operate side by side.

P a g e | 38
Bit-transmission layer
Three different methods are specified for the bit-transmission layer:
• With electrical transmission pursuant to EIA-485, twisted pair cables with
impedances of 150 ohms are used in a bus topology. Bit rates from 9.6 kbit/s to 12
Mbit/s can be used. The cable length between two repeaters is limited from 100 to
1200 m, depending on the bit rate used. This transmission method is primarily used
with PROFIBUS DP.
• With optical transmission via fiber optics, star-, bus- and ring-topologies are used.
The distance between the repeaters can be up to 15 km. The ring topology can also
be executed redundantly.
With MBP (Manchester Bus Powered) transmission technology, data and field bus
power are fed through the same cable. The power can be reduced in such a way that
use in explosion-hazardous environments is possible. The bus topology can be up to
1900 m long and permits branching to field devices (max. 60 m branches). The bit rate
here is a fixed 31.25 kbit/s. This technology was specially established for use in process
automation for PROFIBUS PA.
DIFFERENCES
(Profibus DP and profibus AP)
PROFIBUS DP uses two core screened cable with a violet sheath, and runs at speeds
between 9.6kbit/s and 12Mbit/s. A particular speed can be chosen for a network to give
enough time for communication with all the devices present in the network. If systems
change slowly then lower communication speed is suitable, and if the systems change
quickly then effective communication will happen through faster speed. The RS485
balanced transmission used in PROFIBUS DP only allows 126 devices to be connected
at once; however, more devices can be connected or the network expanded with the
use of hubs or repeaters.

P a g e | 39
PROFIBUS AP is slower than PROFIBUS DP and runs at fixed speed of 31.2kbit/s via
blue sheathed two core screened cable. The communication may be initiated to
minimize the risk of explosion or for the systems that intrinsically need safe equipment.
The message formats in PROFIBUS AP are identical to PROFIBUS DP.
(Profinet and Profibus)
Profinet: an open standard for industrial Ethernet with adaptations for improved real-
time applications. It can directly connect PLCs and IO devices.
Profibus: a fieldbus system for real-time distributed control. It is used for process and
field communication in cell networks with few stations and for data communication. It
connects PLCs, sensors, actuators and other automation devices.
ETHERNET
Ethernet is a family of computer networking technologies for local area
networks (LANs) and metropolitan area networks (MANs).
It’s refined to support higher bit rates and longer link distances. Over time, Ethernet has
largely replaced competing wired LAN technologies such as token ring ,FDDI,
and ARCNET.
The ethernet standard comprise several wiring and signaling variants of the OSI physics
layer in use with Ethernet. The original10BASE5 Ethernet used coaxial cable as
a shared medium. Later the coaxial cables were replaced with twisted pair and fiber
optics links in conjunction with hubs or switches.
Ethernet data transfer rates have been increased from the original 3 megabits per
second (Mbit/s) to the latest 100 gigabits per second (Gbit/s), with 400 Gbit/s expected
by early 2017.

P a g e | 40
CABLE
An electrical cable comprises two or more wires running side by side and bonded,
twisted, or braided together to form a single assembly, the ends of which can be
connected to two devices, enabling the transfer of electrical signals from one device to
the other. Cables are used for a wide range of purposes, and each must be tailored for
that purpose. Cables are used extensively in electronic devices for power and signal
circuits. Long-distance communication takes place over undersea cables. power
cables are used for bulk transmission of alternating and direct current power, especially
using high-voltage cable. Electrical cables are extensively used in building wiring for
lighting, power and control circuits permanently installed in buildings
Electrical cable types
A 250 V, 16 A electrical cable on a reel.
• Coaxial cable: used for radio frequency signals, for example in cable
television distribution systems.
• Communications cable
• Direct-burried cable
• Flexible cable
• Heliax cable
• Non- Metallic sheathed cable (or nonmetallic building wire, NM, NM-B)
• Metallic sheathed cable (or armored cable, AC, or BX)

P a g e | 41
• Multicore cable (consist of more than one wire and is covered by cable jacket)
• Paired cable: Composed of two individually insulated conductors that are usually
used in DC or low-frequency AC applications
• Ribbion Cable: Useful when many wires are required. This type of cable can easily
flex, and it is designed to handle low-level voltages.
• Shielded cable: used for sensitive electronic circuits or to provide protection in high-
voltage applications.
• Single cable (from time to time this name is used for wire)
• Submersible cable
• Twinax cable
• Twin Lead: This type of cable is a flat two-wire line. It is commonly called a 300 Ω
line because the line has an impedance of 300 Ω. It is often used as a transmission
line between an antenna and a receiver (e.g., TV and radio). These cables are
stranded to lower skin effects.
• Twisted Pair: Consists of two interwound insulated wires. It resembles a paired
cable, except that the paired wires are twisted
Twisted pair cabling is a type of wiring in which two conductors of a single circuit are
twisted together for the purposes of canceling out electromagnetic interferences (EMI)
from external sources; for instance, electromagnetic radiation from unshielded twisted
pair (UTP) cables, and crosstalk between neighboring pairs.

P a g e | 42
CONCLUSION
During the project work, the NBM Process Layout was studied. The automation diagram
indicating the connection between Drives and PLCs was also studied. PLC and
DRIVES of ABB were used there and studies was also done on the communication
protocol between the PLC and Drive i.e. Advant FieldBus100 (AF100) and the
communication of the PLC and the HMI (Human Machine Interface) i.e. MB300 was
used. Studies were also made about the Multidrives used for the motors of all the
stands of the mill and how they work.
The recurring problem of bus fault occurred in the past were studied for example
AF#100 Bus Fault in AM1CPU3. To sort out the problem various actions were taken
sequentially finally all the related drives RMIO and TSU’s CON2 power supply of
LU#1&2 were recycled and the problem was solved
Besides the above, various other departments were visited such as Steel melting in LD
shop, Electric arc furnace, Pig iron making through Blast Furnace, Continuous Casting,
Hot Strip Mill, etc where different processes in operation were observed.

PROJECT ON STUDY OF COMMUNICATION PROBLEM IN ABB DRIVE - Copy

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